This document discusses the polymer polysulfone. It provides an introduction to polysulfone, describing its synthesis via polysulfonylation and polyetherification reactions. It discusses the production of major commercial polysulfones by Union Carbide, ICI, and 3M. The properties of polysulfone are summarized, including its high heat resistance, toughness, and chemical resistance. Applications are in electrical components, medical devices, automotive parts, and more due to these desirable properties. The advantages and few limitations of polysulfone are also outlined.

1. SPECIALITY OF
POLYMER
ARJUN SINGH
1508052
POLYMER SCIENCE 3rd year
TOPIC

2. CONTENTS
 INTRODUCTION
 SYNTHESIS
 POLYSULFONE PRODUCTION
 COMMERCIAL POLYSULFONE
 PROPERTIES
 ADVANTAGES
 LIMITATIONS
 APPLICATIONS

3. INTRODUCTION
 Polysulfones were introduced in 1965 by the Union Carbide.
 Polysulfone is an engineering thermoplastic polymers.
 These polymers are known for their toughness, stiffness and stability at high temperature.
 Polysulfone is a class of resinous organic chemical compounds belonging to the family of
polymers in which the main structural chain most commonly consists of benzene rings linked
together by sulfonyl (−SO2−), ether (−O−), and isopropylidene (−C(CH3)2−) groups.
Polysulfone : PSU

4.  They are tough, strong, stiff, and resistant to decomposition by heat or chemical
attack. They retain their mechanical properties over a wide temperature range
(−70° to 150° C, or about −95° to 300° F) and are used as wire coatings, for
fabricoating household and plumbing items, and for automotive parts.
 It is resistant to degradation from hot water and steam.
 They may be processed by extrusion, injection molding and blow molding.
 Due to the high cost of raw materials and processing, polysulfones are used in
specialty applications and often are a superior replacement for polycarbonates.

5. SYNTHESIS
 There are two main routes to the preparation of polysulfones:
1) Polysulfonylation
2) Polyetherification
POLYSULFONYLATION
Polysulfonylation reactions are of the following general types:
The Ar and Ar’ group(s) will contain an ether oxygen, and if Ar=Ar’, then basically identical
products may be obtained by the two routes.

6.  In the polyetherification route,the condensation reaction proceeds by reaction of
types (1) and (2) where M is an alkali metal and X a halide.
 The Ar and Ar’ groups will contain sulfone groups, and if Ar=Ar’, then identical
products maybe obtained by the two routes.
POLYETHERIFICATION

7.  Polyetherification processes form the basis of current commercial polysulfone production
methods. The first commercial polysulfone to be known was udel. The Udel-type polymer
(Union Carbide) is prepared by reacting 4,4’-dichlorodiphenylsulfone with an alkali salt of
bisphenol A.
 In Udel polysulfone mechanism, nucleophilic substitution reaction take place.
Bisphenol A
4,4’-dichlorodiphenylsulfone
Udel (Polysulfone)

8. POLYSULFONE PRODUCTION
 There are five major types of polysulfones made by three companies :
Union carbide – polysulfones
> Udel
> Radel
ICI – polyether sulfones
> Victrex
> Polyether Sulfone 720 P
3M – polyarylether sulfones
> Astrel

9.  The initial commercial polysulfones were synthesised by the nucleophilic
replacement of the chloride from 4,4’-dichlorodiphenylsulfone by anhydrous
sodium salt of bisphenol A. It became commercially availbale in 1966 under the
trade name Udel. It exhibits a reasonably high Tg of 190 degree C.
Udel In 1996 By Union Carbide

10. Radel In 1976
 Union Carbide, in 1976, made available a second-generation polysulfone
under the trade name of Radel. Radel was formed from the reaction of a
bisphenol and bis(p-chlorophenyl)sulfone.This polysulfone exhibits
greater chemical or solvent resistance, a greater Tg of 220degree C,
greater oxidative stability, and good toughness in comparison to Udel.

11. ASTREL (3M CORP)
 In 1967, Minnesota Mining and Manufacturing (3M) introduced astrel
360, an especially high performance thermoplastic, which requires
specialized equipment with extra heating and pressure capabilities for
processing. It has a glass transition temperature of 285 degree C.

12. Victrex
 ICI’s polyether sulfone, victrex was introduced in 1972 and are
intermediate in performance and processing. It has a glass transition
temperature of 230 degree C.

13. POLYETHER SULFONE
 ICI’s polyether sulfone, polyether sulfone was introduced in 1972 and are
intermediate in performance and processing. It has a glass transition
temperature of 250 degree C.

14. COMMERCIAL POLYSULFONES
TYPE OF STRUCTURE Tg TRADE NAME
190oC Udel (union
285oC Astrel (3M Corp)
230oC Victrex(ICI)
250oC Polyether Sulfone
720 P (ICI)
220oC Radel(Union
Carbide)

15. PROPERTIES
 Amorphous in nature.
 High Tg and Tm. Its glass transition temperature is 185 °C.
 Rigid, High strength, Transparent, retainting these properties between -100oC to +150oC.
 High dimensional stability and thermal stability under load.
 Highly resistant to mineral acids, alkali, electrolytes, in pH ranging 2-13.
 High thermal stability is provided by diphenylene sulphone group.
 Transparent orange – yellow in color.
 High in cost due to high cost of raw material.

16.  Low moisture absorption.
 Excellent strength and rigidity up to 320°F continuous use.
 Impact and creep resistant.
 Superior electrical properties.
 High tensile strength and flexural modulus.
 Injection moulding at temperature 335-400 degree C.
 Blow moulding at temperature with 300-360 degree C.
 Resists radiation and flame.

17.  Amorphous in nature because high degree of chain stiffness makes crystallization difficult.
 High heat deformation resistance and chemical stability due to enhanced bond strength
arising from high degree of resonance in the structure.
 Less susceptible to oxidation as sulphur is in its highest oxidation state so electrons are
withdrawn from the benzene rings so that structure is less susceptible to oxidation.
 High Tg and Tm due to high chain aromaticity and high chain stiffness.

18. HIGH HEAT RESISTANCE
 Sulfone polymers are noted for high heat deflection temperatures (HDT) and outstanding
dimensional stability. These strong, rigid polymers are the only thermoplastics that remain transparent
at service temperatures as high as 204°C (400°F). Even after long-term exposure, the resins do not
discolor or degrade.

19. Toughness and Impact Strength
 Sulfone polymers are extremely tough and do not break in standard unnotched impact
tests. They retain their toughness and strength over time, unlike polyetherimide (PEI) which
exhibits a significant loss of impact strength and becomes brittle.
Retention of Tensile Strength

20. Retention of Impact Strength
 Radel® PPSU absorbs significantly higher impact force than polyetherimide (PEI) without cracking or
breaking.

21. Falling Dart Impact Test

22. WATER RESISTANCE
Polysulfone has high water absorption ratio as compared to PC, PEEK, PBT and LCP whereas it
has low water absorption ratio as compared to POM, PEI, PAI and Nylon 66.

23. FLAME RETARDANCE
Material
Limiting oxygen index
(%)
Glass fiber reinforced PPS 47
Polyetherimide (PEI) 47
Polyamide-imide (PAI) 43
Glass fiber reinforced
polyester sulfone (PES)
41
Polyetheretherketone
(PEEK)
35
Polysulfone (PSF) 30
Glass fiber reinforced nylon
66
24
Polybutylene terephthalate
(PBT)
21
Polyacetal (POM) 16

24. Mechanical Properties

25. CONTINUE…

26. General material properties

27. ADVANTAGES
 Lubricated
 Chemical Resistant
 Flame Retardant
 High Heat Resistance
 Good Dimensional Stability
 Good Toughness
 Creep Resistant
 Acid Resistant
 Good Thermal Stability
 Hydrolysis Resistant
 Heat resistance
 Self-extinguishing
 Good electricals

28. LIMITATIONS
 Attacked by some solvents
 Poor weatherability
 Subject to stress cracking
 Processing difficulties
 Increased costs
 Poor solvent resistance
 Cost

29. APPLICATIONS
 Polysulfone is used in electrical applicatons for connectors, switches, and circuit
boards.
 Polysulfone is used as a dielectric in capacitor.

30.  Polysulfones are also used as ignition components.
 Polysulfones are used in transmission parts.

31.  Because of their superior resistance to chemicals and high temperatures,
polysulfones are an excellent choice for components that are exposed to high
temperatures and corrosive media. Examples include printer cartridges, internal
components of coffee machines and battery containers.

32.  Most grades of polysulfones can withstand long term exposure to hot chlorinated
water. Several grades have received approval for food contact and drinking water.
 Polysulfones are also used in the automotive and aerospace industries for
applications where superior thermal and mechanical properties relative to
conventional resins are required.

33.  Used in medical application due to higher biocompatibility.
 Used in membranes for like haemodialysis, water treatment, gas separation etc.

34.  Polysulfone has found growing usage in automotive applications. A key driver has
been replacement of metal and thermoset materials. The main applications of polysulfone are
found under-the-hood such as:
 Battery caps due to its Electrical resistance
 Oil pumps.
 Oil control pistons.
 Transmission parts.
 Carburetor parts.
 Bearing cages, and.
 Ignition components.
Polysulfone are also found in automotive fuses and car headlights (screens, housings and reflectors).
Automotive Applications of Polysulfone

35. THANK YOU